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Water-to-air intercooler installation - 81 931
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Mike9311  



Joined: 14 Dec 2004
Posts: 936
Location: Chicago-ish

PostPosted: Sat Feb 29, 2020 4:55 am    Post subject: Reply with quote

If you look carefully by the distributor cap you can see where I welded the fitting to the intercooler. You might be able to make out how I should have aimed it down a tad. The line is stressed so adding the Tee would help

I also made a Tee in the early 90's for my '80 to hook up my HKS unit. Andial was supposed to sell me an old school proper set up but they dragged their feet so I went HKS. Not sure why I didn't just make something myself back then but I was working on a ton of cars at once plus school.


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1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA M650 Herausnehmbares Dach
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car
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chuck21401  



Joined: 20 Feb 2005
Posts: 297
Location: Annapolis, MD

PostPosted: Sun Mar 01, 2020 4:19 pm    Post subject: Reply with quote

Mike9311 wrote:
https://www.ebay.com/itm/aluminum-intercooler-for-Mazda-RX-7-RX7-FC3S-S4-S5-13B-1986-1992-oilcooler
We have been searching high and low and just discovered the one in the link above. Might still need a few modifications which we are figuring now. Plus fittings of course


So that's an oil cooler rather than a radiator?

This page has a long list of heat exchangers.
http://www.frozenboost.com/water-to-air-heat-exchanger/?osCsid=c822c8514fc40675c1706a4d594c8640

Some are listed as "Oil, Transmission, or Water Radiator/Cooler" while others are listed as "Water to Air Intercooler Radiator."

This one is compact:
http://www.frozenboost.com/water-to-air-heat-exchanger/heat-exchanger-for-oil-p-1103.html



From my 911 days I remembered this vendor, they offer a number of Mocal oil coolers in different sizes

https://www.batinc.net/mocal-cooling
https://irp-cdn.multiscreensite.com/e112be6e/files/uploaded/kits.pdf


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Mike9311  



Joined: 14 Dec 2004
Posts: 936
Location: Chicago-ish

PostPosted: Mon Mar 02, 2020 10:34 am    Post subject: Reply with quote

That top one looks like the common one that is used with this setup. Both Dan and lildude use it with great success. I have driven Dan's CS and its awesome. It seems like we don't need much for this to work effectively except the already mentioned traffic heat soak. It reacts fast though so simply moving forward will get you back to what you want
_________________
1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA M650 Herausnehmbares Dach
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car
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Carrera RSR  



Joined: 08 Jan 2010
Posts: 2069
Location: Somerset, UK

PostPosted: Mon Mar 02, 2020 7:08 pm    Post subject: Reply with quote

What kind of air intake temperatures are people seeing with this TMIC?
What bhp increase is it giving?
_________________
1980 931 - forged pistons, Piper cam, K27/26 3257 6.10 hybrid turbo, 951 FMIC, custom intake, Mittelmotor dizzy & cam pulley, H&S exhaust, GAZ Gold, Fuch'ed, Quaife
Now www.924board.org/viewtopic.php?t=34690
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Mike9311  



Joined: 14 Dec 2004
Posts: 936
Location: Chicago-ish

PostPosted: Tue Mar 03, 2020 1:28 am    Post subject: Reply with quote

Carrera RSR wrote:
What kind of air intake temperatures are people seeing with this TMIC?
What bhp increase is it giving?


I will let you know soon. Will be installing another dual temp gauge

If everything works out for this year I will get it dyno'd as well
_________________
1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA M650 Herausnehmbares Dach
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car
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Carrera RSR  



Joined: 08 Jan 2010
Posts: 2069
Location: Somerset, UK

PostPosted: Tue Mar 03, 2020 1:33 am    Post subject: Reply with quote

Mike9311 wrote:
Carrera RSR wrote:
What kind of air intake temperatures are people seeing with this TMIC?
What bhp increase is it giving?


I will let you know soon. Will be installing another dual temp gauge

If everything works out for this year I will get it dyno'd as well


That would be great. We have a turbo in the UK with this TMIC. Would like to get some added info for the owner.
_________________
1980 931 - forged pistons, Piper cam, K27/26 3257 6.10 hybrid turbo, 951 FMIC, custom intake, Mittelmotor dizzy & cam pulley, H&S exhaust, GAZ Gold, Fuch'ed, Quaife
Now www.924board.org/viewtopic.php?t=34690
Then www.924board.org/viewtopic.php?t=31252
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chuck21401  



Joined: 20 Feb 2005
Posts: 297
Location: Annapolis, MD

PostPosted: Tue Mar 03, 2020 5:29 am    Post subject: Reply with quote

Mike9311 wrote:
That top one looks like the common one that is used with this setup. Both Dan and lildude use it with great success. I have driven Dan's CS and its awesome. It seems like we don't need much for this to work effectively except the already mentioned traffic heat soak. It reacts fast though so simply moving forward will get you back to what you want


Good to know. The smaller one is inexpensive so I might start there. Dan's last update said that he was pulling together the parts list and the rear mounting brackets are being fabricated. So I hope to start on the actual install soon.

I would like to include a dedicated expansion tank...I'm thinking the 944 one should work?
(94410612506). Used (but yellowed) ones are cheap on Ebay. Lindsey racing has a shiny tank that would make a nice upgrade at some point...mostly for the bling.

https://www.lindseyracing.com/LR/Parts/944COOLINGSYSBILLET.html


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Carrera RSR  



Joined: 08 Jan 2010
Posts: 2069
Location: Somerset, UK

PostPosted: Tue Mar 03, 2020 6:25 am    Post subject: Reply with quote

I'd prefer the non bling version ......
_________________
1980 931 - forged pistons, Piper cam, K27/26 3257 6.10 hybrid turbo, 951 FMIC, custom intake, Mittelmotor dizzy & cam pulley, H&S exhaust, GAZ Gold, Fuch'ed, Quaife
Now www.924board.org/viewtopic.php?t=34690
Then www.924board.org/viewtopic.php?t=31252
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Mike9311  



Joined: 14 Dec 2004
Posts: 936
Location: Chicago-ish

PostPosted: Wed Mar 04, 2020 12:29 am    Post subject: Reply with quote

Carrera RSR wrote:
Mike9311 wrote:
Carrera RSR wrote:
What kind of air intake temperatures are people seeing with this TMIC?
What bhp increase is it giving?


I will let you know soon. Will be installing another dual temp gauge

If everything works out for this year I will get it dyno'd as well


That would be great. We have a turbo in the UK with this TMIC. Would like to get some added info for the owner.


What gauge are you using? I went through your build thread and either missed it or its not mentioned? I'm looking at a couple but haven't decided
_________________
1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA M650 Herausnehmbares Dach
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car
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Carrera RSR  



Joined: 08 Jan 2010
Posts: 2069
Location: Somerset, UK

PostPosted: Wed Mar 04, 2020 12:48 am    Post subject: Reply with quote

Mike9311 wrote:

What gauge are you using? I went through your build thread and either missed it or its not mentioned? I'm looking at a couple but haven't decided


Zeitronix ZT2 dash mounted unit is used for display and logging ...
AFR
EGT
Boost
Intake temp pre and post FMIC (can only read one at a time, I have a cabin switch and toggle between them)

Current pre IC is up to 90degC on a long pull, used to be 125degC with 2660 6.10. Post IC is just 6-8degC above ambient air temperature. This is at 1.0 - 1.1 bar boost.

It also controls the RPM boost enrichment solenoid switch, limits boost signal to WUR up to 4400rpm to avoid rich AFR in the mid range.
_________________
1980 931 - forged pistons, Piper cam, K27/26 3257 6.10 hybrid turbo, 951 FMIC, custom intake, Mittelmotor dizzy & cam pulley, H&S exhaust, GAZ Gold, Fuch'ed, Quaife
Now www.924board.org/viewtopic.php?t=34690
Then www.924board.org/viewtopic.php?t=31252
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chuck21401  



Joined: 20 Feb 2005
Posts: 297
Location: Annapolis, MD

PostPosted: Wed Mar 04, 2020 8:04 am    Post subject: Reply with quote

Carrera RSR wrote:
Post IC is just 6-8degC above ambient air temperature. This is at 1.0 - 1.1 bar boost.


That's impressive.
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Carrera RSR  



Joined: 08 Jan 2010
Posts: 2069
Location: Somerset, UK

PostPosted: Wed Mar 04, 2020 8:51 am    Post subject: Reply with quote

chuck21401 wrote:
Carrera RSR wrote:
Post IC is just 6-8degC above ambient air temperature. This is at 1.0 - 1.1 bar boost.


That's impressive.


Its a heafty lump of 951 turbo aluminium FMIC and hard to heat up. Works well with the Bumper mounted ductIng
_________________
1980 931 - forged pistons, Piper cam, K27/26 3257 6.10 hybrid turbo, 951 FMIC, custom intake, Mittelmotor dizzy & cam pulley, H&S exhaust, GAZ Gold, Fuch'ed, Quaife
Now www.924board.org/viewtopic.php?t=34690
Then www.924board.org/viewtopic.php?t=31252
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chuck21401  



Joined: 20 Feb 2005
Posts: 297
Location: Annapolis, MD

PostPosted: Wed Mar 25, 2020 1:28 am    Post subject: Reply with quote

I'm stuck at the moment. Still waiting on the rear mounting bracket to ship.

I pulled up an archive of the parts installation list so will work on acquiring these parts.


(4) 2.25" T-bolt clamps
(2) 2.25" silicone 45 elbows (black)
3/4" Remote inline filler cap
Bosch intercooler pump
(4) brass 1/2" NPT Male to 3/4" barbed 90 elbows for intercooler or heat exchanger
(2) brass 1/2" NPT Male to 3/4" barbed straights for intercooler or heat exchanger
10 feet of 3/4" flexible fluid lines
(6) 3/4" worm gear clamps
10-row radiator (11.5" x 5.75" x 2")
2.25" cast aluminum tight radius 90 elbow

Are T-bolt clamps that much better than the stock hose clamps? ( 999.512.349.02). They just look a little "fast and furious" to me.

I also plan to include a 944 expansion tank in the system.

Where is a good place to mount the intercooler pump?
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Mike9311  



Joined: 14 Dec 2004
Posts: 936
Location: Chicago-ish

PostPosted: Wed Mar 25, 2020 4:39 am    Post subject: Reply with quote

At the moment there isn't any bracket on mine. Its totally fine especially for testing


Did you get your Pump with the ford bracket? Its mounted where the horns go. Nice and low. Also no expansion tank. This doesn't get as hot as the radiator. Just an inline hose fill up high so it can be used to bleed the system. This doesn't get as hot as the radiator

Not sure how long this image will be up on ebay


_________________
1980 931 since 1989
1981 Ideola 931 Club Sport
1982 931 Entwicklungsfahrzeug
1979 924 NA M650 Herausnehmbares Dach
1982 931 Red Resurrection - 951 IC
1982 931 parts car / resurrection?
1980 924 NA (R&D lightweight)
1982 931 wana-be GTR race car
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View user's profile Send private message
chuck21401  



Joined: 20 Feb 2005
Posts: 297
Location: Annapolis, MD

PostPosted: Wed Mar 25, 2020 5:17 am    Post subject: Reply with quote

Thanks for the info.

I haven't purchased the pump yet.

Was looking at this one as this supplier has other parts I'll need.

http://www.siliconeintakes.com/liquid-air-adapter/water-to-air-pump-0392022002-p-1001.html

Haven't seen that bracket before until you posted it....looking around now...looks like it's available from Summit

https://www.summitracing.com/parts/fms-m-8501-msvt?rrec=true

and other places with part number M-8501-MSVT

Still would need the pigtail connector, apparently that is sold separately.
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